Hustler X-ONE BAC-VAC OPERATOR S MANUAL

Transcription

1 Hustler X-ONE BAC-VAC OPERATOR S MANUAL 00 South Ridge Road Hesston, Kansas REV C

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3 Table of Contents General Information To The New Owner Using This Manual Warranty Registration Parts and Service Safety Precautions Safe Operation and Service Precautions Safety and Instruction Decals Assembly Instruction Packing List Hustler X-ONE BAC-VAC Deck Adapter Kits Mower Deck Preparation (8 ) & 90 ( ) Adapter Assembly (0 X-ONE) Adapter Assembly Mower Preparation BAC-VAC Mount Assembly Frame Cover Assembly Installation Final Connection BAC-VAC Assembly Weight Assembly Operation Vacuum Pickup and Collection Unloading the BAC-VAC Converting To Side Discharge Mode Removing The BAC-VAC Maintenance & Storage Blower Housing and Flex Tube Maintenance Blower Drive Belt BAC-VAC Hopper BAC-VAC Hopper Switch Adjustment Blower Impeller Storage Parts List toc- REV C

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5 GENERAL INFORMATION To The New Owner The purpose of this manual is to assist owners and operators in maintaining and operating the Hustler X-ONE BAC-VAC. Please read it carefully; information and instructions furnished can help you achieve years of dependable performance. Using This Manual General operation, adjustment and maintenance guidance is outlined for both the experienced and novice Hustler user. Operating conditions vary considerably and cannot all be addressed individually. Through experience, however, operators should find no difficulty in developing good operating skills suitable to most conditions. Directions used in this manual, for example RIGHT or LEFT, refer to directions when in operator position and facing forward, unless otherwise stated. Photographs and illustrations used were current at the time of printing, but subsequent production changes may cause your machine to vary slightly in detail. Hustler Turf Equipment reserves the right to redesign and change the machine as deemed necessary, without notification. If a change has been made to your machine which is not reflected in this operator s manual, or the parts manual, see your Hustler Dealer for current information and parts. Warranty Registration within ten (0) days following date of purchase to validate your warranty protection. As the new equipment owner, you should confirm that your Hustler Dealer has registered your attachment with Hustler Turf Equipment. Be sure to register the mower plus each attachment that displays a model and serial identification number plate with Hustler Turf Equipment. IMPORTANT: Any unauthorized modification, alteration, or use of non-approved attachments voids the warranty and releases Hustler Turf Equipment from any liability arising from subsequent use of this equipment. Do not use or operate any attachment which is not approved by Hustler Turf Equipment. Parts and Service Use original Hustler replacement parts only. These parts are available through your local Hustler Dealer. To obtain prompt, efficient service, always provide the following information when ordering parts:. Correct part description.. Correct part number.. Correct model number.. Correct serial number. All warranty repair and service must be handled through an authorized Hustler Dealer. Arrangements should be made through your local service center. Your Hustler Dealer must register this attachment on-line 79 - REV C

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7 SAFETY PRECAUTIONS This safety alert symbol is used to call attention to a message intended to provide a reasonable degree of PERSONAL SAFETY for operators and other persons during the normal operation and servicing of this equipment. DANGER denotes immediate hazards which WILL result in severe personal injury or death. WARNING denotes a hazard or unsafe practice which COULD result in severe personal injury or death. This manual uses two other words to highlight information. IMPORTANT calls attention to special mechanical information and NOTE emphasizes general information worthy of special attention. All operators and mechanics should read this manual, and be instructed about safe operating and maintenance procedures. Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety alert symbol, which means DANGER or WARNING - personal safety instructions. Failure to comply with the instructions may result in personal injury or death. Incorrect usage of this attachment may result in severe injury. Personnel operating and maintaining it should be trained in the proper use and should read the manuals completely and thoroughly before attempting to set-up, operate, adjust, or service this mower. Safe Operation and Service Precautions Evaluate the terrain to determine what accessories and attachments are needed to properly and safely perform the job. Only use accessories and attachments approved by the manufacturer. Always stop on level ground, disengage the deck clutch, place the steering control levers in the park brake position, stop the mower s engine and remove the ignition key before leaving the operator s seat for any reason including unclogging the chute. Always be aware of any obstructions, especially small children, when backing or unloading the hopper. Always keep safety shields and covers in place, except for servicing. Never work on the blower assembly or the mower deck when the mower s engine is running. Never operate machine with the hopper in the open position except for unloading. Never attempt high speed maneuvering in crowded or congested areas. Always operate with the complete BAC-VAC system, mulching system or side discharge chute in place and in the lowest position. Always keep clear of the mower blades and attachments during their operation. Turn off the blades when not mowing. Stop the engine before removing the BAC-VAC or unclogging the discharge chute. Never clear the discharge chute with the engine running. Turn off the engine and be sure the blades have stopped before cleaning. Use a probe to clear a plugged discharge area. Never use your hand! Clean flammable material from the machine. Prevent fires by keeping the engine compartment, exhaust area, battery, fuel line, fuel tank and operator s station clean of accumulated trash, grass clippings, and other debris. Always clean up spilled fuel and oil. Grass collection system components are subject to wear, damage and deterioration, which could expose moving parts or allow objects to be thrown. Frequently check components and replace with manufacturer s recommended parts when necessary. Never direct discharged material toward anyone. Avoid discharging material against a wall or obstruction. Material may ricochet back toward the operator. Always disengage the blades and wait for them to stop before crossing gravel drives, walks or roads. Safety and Instruction Decals The decals are designed to give the operator brief information needed in the daily operation and service of the mower. These decals are not intended to be used in place of this manual but instead are to be used as an extension of this manual. These decals should not be removed or obliterated. Replace these decals if they become unreadable. It is the owner s responsibility to make certain that the operators and mechanics read and understand this manual and all decals before operating this mower. It is also the owner s responsibility to make certain that the operators and mechanics are qualified and physically able individuals, properly trained in the operation of this equipment. All operators and mechanics must become familiar with the safe operation of the equipment, operator controls and decals. Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator REV C

8 The owner/user can prevent and is responsible for accidents or injuries occurring to themselves, other people or property. The owner should also ensure that the operators/mechanics know that they are responsible for their own safety as well as the safety of other persons within the vicinity. Remember, the operator is responsible for accidents or hazards occurring to other people or their property. The following illustrations show the various safety decals that are located on the mower. A brief explanation, for those requiring one, is shown to help the operator understand the meanings of these decals. WARNING Specific safety warning decals are located on the equipment near the immediate areas of potential hazards. These decals should not be removed or obliterated. Replace them if they become non-readable. WARNING: Thrown objects! Part Number 0 Never operate the mower deck with side deflector damaged, altered, removed or in raised position, except when the entire grass catcher attachment or mulching system is being used. Part Number 087 DANGER: Rotating blades, pulleys & belts Keep hands, feet and clothing away. Keep shields or covers in place while machine is in operation. Part Number 0 Part Number 077 Read Operator s Manual before attempting to operate this machine. DANGER: Rotating impeller 0 Wear ear protection, eye protection and safety shoes when operating this equipment. 077 Keep hands, feet and clothing away. Keep shields or covers in place while machine is in operation. Stop engine, remove ignition key. Engage park brake. Use a probe to clear debris from blower assembly. Remove blower chute to clear debris from chute. Never engage mower deck unless the entire grass catcher attachment is properly installed. REV C - 79

9 Part Number 090 Part Number 097 WARNING Crushing body WARNING Crushing hand or foot 090 Stay clear of raised hopper door. Never get between the hopper door and the hopper container. Do not reach or climb into the hopper. Never reach into the hopper door opening or hopper door linkage area. 097 Never reach into the crushing danger zone. Keep hands and feet away REV C

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11 ASSEMBLY INSTRUCTION These instructions apply to the assembly of the Hustler BAC-VAC to a Hustler X-ONE 8,, or 0 mower. It is intended that these units be installed by trained Hustler service personnel. If additional assistance is required, contact the Hustler Customer Service Department. Directions given in these instructions, for example left and right, refer to direction while seated on the mower. Before proceeding, read thru the following instructions to familiarize yourself, while at the same time identify and inventory kit parts supplied. Unpack and inspect all parts. Notify carrier of any shipping damages immediately. Packing List Hustler X-ONE BAC-VAC Part No. Description Qty NA BAC VAC ASSEMBLY NA WEIGHT MOUNT F/A NA CONTROL PANEL 0 BLOWER F/A WEIGHT 0LB 787 MOUNT, LH 907 MOUNT, RH 790 MOUNT SPACER 07 FLEX TUBE 09 WIRING HARNESS 077 MUFFLER EXTENSION 000 WIRE TIE NT.00- HX G ZN 8 08 CS 0.7- X.00 HX G 07 CS X.70 HX G 00 HP.8 X.90 ZN 09 CB.7-X.000 G 0 CS 0.-8 X.000 HX G 070 CE.0 X.00 X.0 X.8 ZN 00 NT 0.7- HX G 0788 FW.0 X.70 X.8 ZN 080 NT.7- HX G ZN NY 09 UB.7-X.00X.00 SQ 7078 FW.X.X.0 ZN 709 CS X.0 HX G 779 FW.0 X.8 X.00 SAE 779 FW. X.0 X.09 SAE 0 78 FW 0. SAE SC #0 X.70 PHILLIPS 080 CS.-8 x.7 HXG 97 INLET TUBE NOTE: 97 and 0 are located in the BAC-VAC hopper. They can be retrieved after the hopper and wire harness are installed and operational. Deck Adapter Kits The following adapter kits must be used when mounting the 79 - REV C

12 BAC-VAC to a particular deck. Deck Size Adapter Kit P/N Mower Deck Preparation. Park the mower on a flat surface. Always place the deck clutch switch in the disengaged position, place the steering control levers in the park brake position and shut off the ignition switch and remove the key from the switch. Disconnect the negative battery cable.. Remove the discharge chute and torsion spring. NOTE: Retain these parts as they will be re-installed when the BAC-VAC is removed.. Release the deck drive belt tension.. Remove the existing spindle bolt and pulley from the center blade spindle.. Replace the pulley with the double pulley and place the new cup washer between the head of the new bolt and the drive pulley. Thread the cup washer and bolt assembly into the spindle shaft. Torque bolt to 8 ft.-lbs. Refer to Figure - or Figure -.. Attach the deck blowout baffles to the underneath side of the deck. Refer to Figure - or Figure -. NOTE: These baffles replace the existing adjustable baffles provided with the deck. NOTE: The blowout baffles are most useful in dry, dusty conditions, particularly when picking up leaves. In other conditions, the adjustable baffles, supplied with the deck, may provide better cut quality and dispersion than the blowout baffles. 7. Attach the blower baffle to the deck. Refer to Figure - or Figure Assemble the blower mount to blower assembly. Refer to Figure - or Figure -. NOTE: The 8 / blower mount has two sets of holes. Use the rear set of holes when attaching to a 8 deck. Use the front set of holes when attaching to a deck. Figure - 9. Attach the blower assembly to the deck by inserting the rod through the discharge chute bracket and blower mount and secure with nut. Refer to Figure - or Figure Place the deck drive belt around the lower pulley of the double pulley. Confirm that the belt is properly routed and seated on all pulleys and idlers. Re-tension the deck drive belt per the tensioning instructions found in the mower s General Service Manual.. Install and route the blower belt around the blower pulleys and the upper pulley on the double pulley. This belt is self tensioning. Figure -. 8 / decks only Remove the lower nut from the right front deck chain attaching bolt. Slide the blower belt cover mount bracket onto the bolt and re-install the nut and tighten. Figure -. 0 decks only Remove the front right side deck lift chain and attach the rigid link () to the deck lift arm. Position the center drive bracket (77) on the deck as shown and attach it and the rigid link () to the deck. NOTE: The rigid link () must move freely in the top slot and rotate freely in the bottom hole.. Attach the blower belt cover. Refer to Figure - or Figure -. WARNING Do not operate deck without discharge chute or complete BAC-VAC system in place. REV C - 79

13 900 (8 ) & 90 ( ) Adapter Assembly INDEX NO. PART NO. DESCRIPTION 0 BLOWER OUTLET TUBE 0 OUTLET ADAPTER 09 CB.7- X.00 G ZNY 779 FW.0 X.8 X.00 SAE 00 NT.7- HX GRD ZNY 0 CS.7- X.000 HX G 7 9 BLOWER MOUNT Existing hardware Discharge cover 8 mount hole Blower assembly mount hole BLOWER BELT COVER, 8" BLOWER BELT COVER, " (INCLUDES DECALS) BELT, A 97.0" EL, 8 BELT, A 0.0 EL, 0 07 CS.00- X.70 HX G 78 CW. X. X.0 BLK DOUBLE PULLEY, 8" DOUBLE PULLEY, BELT COVER BRACKET, 8" BELT COVER BRACKET, 009 CN.-8 X.00 MAX THK 7900 KNOB /-8 X /" BLOWER BAFFLE, 8" BLOWER BAFFLE, RH BLOWOUT BAFFLE, 8" RH BLOWOUT BAFFLE, NT.7- HXZY NL 9 0 DECAL DECAL Existing hardware LS BAFFLE, 8 LS BAFFLE, Existing hardware Existing hardware 8 NOTES:. Bracket shown for 8 deck. deck bracket formed opposite. 8 7 Install in lower set of holes Figure REV C

14 Outlet tube and adapter assembly 90 (0 X-ONE) Adapter Assembly Existing hardware 8 Discharge cover Existing hardware 9 7 Existing hardware Blower assembly 0 Existing rod 9 Existing hardware Existing hardware Existing hardware Existing hardware 0 Install in lower set of holes Figure - INDEX NO. PART NO. DESCRIPTION 0 CENTER DRIVE COVER (INCLUDES DECALS) " EL A-SEC BELT RS BLOWOUT BAFFLE 7 BLOWER BAFFLE 8 BLOWER MOUNT 7900 KNOB /-8 X /" 7 RIGID LINK 8 77 CENTER DRIVE BRACKET 9 0 0" DOUBLE DRIVE PULLEY 0 78 CW. X. X.0 BLK 07 CS.00- X.70 HX G 0 CS.7- X.000 HX G 09 CB.7- X.00 G ZNY 779 FW.0 X.8 X.00 SAE 00 NT.7- HX GRD ZNY 080 NT.7- HXZY NL CN.-8 X.00 MAX THK 8 0 DECAL DECAL LS BAFFLE REV C - 79

15 Blower belt Muffler outlet tube Mower Preparation Figure - WARNING Allow engine and muffler to cool before assembling the unit to the mower.. Attach the muffler extension to the muffler outlet tube. Figure - IMPORTANT: Tailpipe and tailpipe extension become very hot during operation. These parts must not be allowed to contact the catcher shell during operation or while the mower is hot.. Remove the two cap screws that attach the left side of the INDEX NO. PART NO. DESCRIPTION 07 MUFFLER EXT.. (KAWASAKI ENGINES) 7999 SC #0 X.70 PHILLIPS Figure - rear bumper to the mower frame. Figure -. Attach the left side mount to the rear bumper and the mower frame using the hardware shown. Figure -. Repeat steps & for the opposite side. Figure -. Attach the mount spacer to the left and right mounts as shown. Figure -. Tighten all hardware REV C

16 BAC-VAC Mount Assembly 8 Rear bumper 7 8 INDEX NO. PART NO. DESCRIPTION 790 MOUNT SPACER 789 MOUNT, RS MOUNT, LS 07 CS.00- X.70 HX G 779 FW. X.0 X.090 SAE 0089 NT.00- HX G ZNYC FW.0 X.70 X.8 ZNYC CS.00- X.0 HX G ZN Figure - Frame Cover Assembly Installation. Raise the seat and seat platform to allow access to the area underneath the seat.. The BAC-VAC frame harness should be routed on the mower as shown. Figure - REV C - 79

17 Existing left side frame cover Frame wire harness Frame wire harness Remove this hardware Figure -. Remove the existing left side frame cover and right side frame cover from the mower. Figure -7 & Figure -8 Figure -8 Wire harness Hose clamp Right side frame cover Figure -7. Unbolt the hose clamp from the mower frame that the wiring harness to the control panel goes through. Do not remove the wiring harness from the clamp. Figure -9. Route the BAC-VAC frame harness pigtail that has the two connector bodies through the hose clamp and retighten clamp hardware. Figure -9. Remove the mower s control panel. 7. Locate the auxiliary connector body underneath the control panel and remove the cap. Figure Plug the BAC-VAC frame harness connector into the auxiliary plug. Figure - 9. Secure the BAC-VAC frame harness to the main mower harness with a wire tie. Figure - 0. Re-attach the mower control panel. Make sure that the wiring harnesses are routed through the slot in the bottom of the control panel correctly.. Re-attach the right frame cover to the mower frame.. Route the BAC-VAC frame harness as shown (Figure Figure -9 -) and connect the appropriate wires to the battery terminals. Secure the BAC-VAC frame harness to the mower using the wire ties as shown. Make sure that none of the harness will come in contact with any moving parts. Figure - & Figure -. Attach the three wires on the wiring harness to the BAC- VAC switch. Figure -. Attach the left frame cover assembly to the mower frame. Figure -. Route the BAC-VAC frame harness along the left side of the mower frame as shown. Secure the harness to the mower using the wire ties as shown. Figure -7 & Figure REV C

18 Auxiliary connector body Cap Figure -0 Auxiliary connector body BAC-VAC frame harness BAC-VAC frame harness connector Figure - Figure - BAC-VAC frame harness Wire ties Black wire Wire ties Wire tie + Battery terminal Red wire Battery terminal Figure - Final Connection Main mower harness Figure -. Park the mower on a flat surface. Always place the deck clutch switch in the disengaged position, place the steering control levers in the park brake position and shut off the ignition switch and remove the key from the switch. Disconnect the negative battery cable.. Roll the BAC-VAC to the mower and slide the lower hooks over the rod on the mount tube. Figure - NOTE: It is recommended that two people attach the hopper to the mower mounts. One person to roll the hopper into position, slide the lower hooks onto the mount spacer and pivot it into position. The second person to insert the clevis pins, flat washers, and hair pins thru the REV C -8 79

19 Blue Orange/blue Switch Orange/white Wire tie Figure - BAC-VAC frame harness Frame cover BAC-VAC frame harness Figure -7 Figure - side mount brackets and the BAC-VAC mount tubes. Figure -. Connect the BAC-VAC frame harness connector body to the hopper s harness connector body. Figure -0. Raise the discharge cover on the blower housing. Slide the outlet adapter into place on the blower outlet. Secure in place with the discharge cover latching the rod handle of the outlet adapter. Refer to Figure - or Figure -.. Using the switch, open the BAC-VAC hopper and retrieve the flex tube and inlet tube bracket. Attach the inlet tube bracket to the BAC-VAC hopper by securing it to the inlet baffle on the inside of the hopper. Figure -. Slide one end of the flex tube onto the blower outlet tube. Figure - 7. Slide the other end of the flex tube over the inlet tube. Figure - BAC-VAC frame harness Wire tie Figure Attach the counterweight mount by securing it with cap screws to the footrest. Figure REV C

20 Frame cover BAC-VAC frame harness connector body Hooper harness connector body CS. x.00 FW. x.87 Figure Attach the four auxiliary weights to the weight mount as shown. Figure - 0. Attach the counter weight mount to the front of the mower. Figure - NOTE: When attaching the counter weight mount to a frame for a 8 deck, the inside set of holes is used for the u-bolts to attach to the front wheel arms.. Slide the weights vertically onto the mount and lock in place using the weight lock plate and tighten knobs. Figure -0 Figure -. Reconnect the negative battery cable.. Increase the mower s drive tire s pressure to psi (0 KPa). The drive tires will need to have to the air pressure increased to support the additional weight of the BAC- VAC system and when grass clippings are in the hopper. NOTE: When the BAC-VAC system is removed the air pressure in the tires should be decreased to the normal operating range of 8 - psi ( - 8 KPa).. REV C -0 79

21 BAC-VAC Assembly Hopper assembly INDEX NO. PART NO. DESCRIPTION 070 CE.0 X.0 X. X FW. X.00 X.0 ZN 00 HP.8 X.90 ZN Figure - Mount tube Hooks Figure - INDEX NO. PART NO. DESCRIPTION 97 INLET TUBE 080 CS.-8 x.7 HXG 78 FW. X.87 X.0/.080H Figure REV C

22 Inlet tube Flex tube Blower outlet tube Figure - REV C - 79

23 Weight Assembly 7 8 /0" DECK " DECK INDEX NO. PART NO. DESCRIPTION WEIGHT LOCK PLATE 7900 KNOB /-8 X /" 7 WEIGHT MOUNT BUMPER 09 CB.7- X.00 G ZNY 007 WEIGHT NT.7- HXZY NL FW.0 X.8 X.00 SAE 9 09 UB.7- X.00 X.00 SQ 0 WEIGHT 0 LBS 08 CS.7-X.00 HX G ZN 00 NT.7- HX G ZN Figure REV C

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25 OPERATION Vacuum Pickup and Collection Follow normal mower start-up and operating procedures as outlined in the mower operator s manual. The blower will operate when the mower deck clutch switch is engaged. To stop the blower, return the deck clutch switch to the disengaged position. Proceed to mow in the normal manner and occasionally glance at the flex tube. When the hopper is full the speed of debris through the tube will decrease. When the hopper is filled, move the deck clutch switch to the disengaged position and drive the machine to the unloading area. It is best that the hopper be unloaded before the discharge chute and flex tube areas become clogged. If clogging occurs, it will be necessary to clear the blower chute and flex tube areas of all material before starting to mow again. WARNING Make certain the engine is turned off, the steering control levers are in the park brake position and the ignition key is removed from the ignition switch and be sure blades have stopped before clearing the blower chute and flex tube areas. WARNING Never place hands or feet into the discharge area. The impeller is relatively close to the housing and will cause severe injury. Use a probe to clean debris from blower housing discharge area. The discharge cover must remain closed whenever the blower chute is removed. WARNING Never engage mower deck unless BAC-VAC flex tube is in place on the BAC-VAC inlet tube and inserted onto blower chute outlet tube. WARNING Prevent objects being thrown and the accumulation of grass clippings and other debris in engine compartment by NEVER operating mower deck unless: BAC-VAC is in the catching position. Flex tube is in place on the blower chute and on the BAC-VAC inlet tube. Only operate when hopper door is fully closed. Unloading the BAC-VAC WARNING Make certain the deck clutch switch is in the disengaged position before unloading. The BAC-VAC is designed to dump it s load in a designated area on the ground while the mower is stationary. To dump the BAC-VAC, place the steering control levers in the park brake position to prevent accidental mower movement or engine cutting in and out. NOTE: The mower s ignition switch must be in the ON position to open or close the hopper door. WARNING Never approach the BAC-VAC hopper while the mower s ignition switch is in the ON position. Hold the BAC-VAC operating switch in the open position until the hopper door comes to a stop. Keep the hopper door open until all of the clippings have been discharged from the hopper. Then close the hopper door by holding the operating switch in the closed position until the hopper door has closed all the way. The deck clutch switch may then be engaged to continue mowing. WARNING Never work on the blower assembly or the mower deck when the mower engine is running. Converting To Side Discharge Mode. Park the mower on a flat surface. Turn engine off, place the steering control levers in the park brake position and remove the ignition key. Be sure blades have stopped before dismounting from the mower.. Remove the flex tube from the BAC-VAC inlet tube and blower outlet tube. Figure -. Remove the blower outlet tube from the blower assembly. Figure -. Remove the blower belt cover from the deck. Figure -. Release the tension from the blower drive belt and remove it. Figure - NOTE: It is not necessary to remove the double pulley on the deck spindle.. Remove the pin that connects the blower to the discharge chute bracket tabs and remove the blower housing. Figure - 7. Assemble the torsion spring, original discharge chute and pin to the bracket tabs. Make sure the torsion spring is 79 - REV C

26 assembled as shown so that it applies pressure to the discharge chute and keeps it in the down position. Figure - 8. Remove the blower baffle and replace it with the right side adjustable baffle that was provided with the deck. Figure - or Figure Remove the BAC-VAC from the rear of the machine. (See Removing the BAC-VAC section below. NOTE: It is not necessary to remove the BAC-VAC frame that is attached to the rear of the mower. Tall pulley cover Discharge chute WARNING Torsion spring Never operate the mower deck with side deflector damaged, altered, removed or in raised position, except when the entire BAC-VAC attachment or mulching system is being used. WARNING Always operate with complete BAC-VAC, mulching system or side discharge chute in place and in the lowest position. Flex tube Inlet tube Figure - Removing The BAC-VAC Use the following procedure when removing the BAC- VAC from the mower.. Park the mower on a flat surface. Turn engine off, place the steering control levers in the park brake position and remove the ignition key. Be sure blades have stopped before dismounting from the mower.. Disconnect the BAC-VAC frame harness from the hopper s wire harness.. Remove the flex tube from the BAC-VAC inlet tube. Figure -. Unpin the BAC-VAC assembly from the side mount brackets and pivot it until the lower hooks clear the mount spacer. Figure - Pin Blower outlet tube BAC-VAC Blower belt cover Figure - Unpin here Hook Blower belt Unpin here Figure - Double pulley Figure - Pin NOTE: It is recommended that two people remove the hopper from the mower mounts. The first person to hold the hopper in place while the second person removes the clevis pins, flat washers, and hair pins from the side mount brackets and the BAC-VAC mount tubes. The first person will then pivot the hopper away from the side REV C - 79

27 mount brackets, slide the lower hooks off the mount tube and roll it away from the mower.. Re-insert the latching pins into frame mount for storage. Secure in place with the hair pins. Tuck the BAC-VAC frame harness under the left side latching pin for protection. Figure -. Roll the BAC-VAC away from the mower. BAC-VAC frame harness Latching pin Figure REV C

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29 MAINTENANCE & STORAGE Blower Housing and Flex Tube Maintenance To clean the BAC-VAC, hand wash with soap and water; rinse with clean water. WARNING Never work on the blower assembly or mower deck when the engine is running. WARNING Clean flammable material from machine. Prevent fires by keeping engine compartment, top of deck, exhaust area, battery, hydraulic lines, fuel line, fuel tank and operator s station clean of accumulated trash, grass clippings, and other debris. Always clean up spilled fuel and oil. The blower assembly, flex tube and blower outlet tube (Figure -) should be kept clean and free of any accumulation of clippings or other obstructions. Occasional clogging may also occur when working in heavy or wet grass. WARNING Never place hands or feet into the blower chute. There is an impeller located inside the housing that will cause severe injury. Use a probe to clear debris from blower chute. Flex tube Blower assembly Blower Drive Belt Blower outlet tube Figure - The blower drive belt (Figure -) is located under the blower belt cover. This belt is spring tensioned and should not need adjustment. To inspect or replace the belt, remove the blower belt cover from the top of the deck and the blower housing. When belt replacement becomes necessary, check the condition of the pulleys. Clean the grooves and check for excessive wear. A new belt should not run against the bottom of groove. If it does bottom out, the pulley needs replacing. WARNING Never operate the mower deck with side deflector damaged, altered, removed or in raised position, except when the entire BAC-VAC or mulching system is being used. Blower belt WARNING Prevent objects being thrown and the accumulation of grass clippings and other debris in engine compartment by NEVER operating mower deck unless: BAC-VAC is in the catching position. Flex tube is in place on the blower chute and on the BAC-VAC inlet tube. Only operate when hopper door is fully closed. To service the blower housing: remove the blower belt cover from the top of the deck and blower housing. To service the flex tube, remove the tube from the unit. The tube can be cleaned by using soapy water and washing the inside of the tube with a pressure washer. Rinse with water. BAC-VAC Hopper Figure - Use a pressure washer to clean the inside and outside of the hopper. NOTE: Do not spray the linear actuator with the pressure washer. It will be necessary to lubricate the three grease points shown in Figure - every 0 hours or after every power washing. NOTE: It will be necessary to remove the actuator 79 - REV C

30 cover to access the center grease zerk. Angled sensor switch plunger Control box Horizontal sensor switch plunger Screws Screws Grease zerks Figure - BAC-VAC Hopper Switch Adjustment Occasionally it may be necessary to adjust the sensor switches on the hopper door. These switches, when adjusted properly, make sure that the hopper door is closing and sealing properly.. Ensure that the BAC-VAC is fully mounted and that the hopper wire harness and the mower frame harness are connected.. With the hopper door closed, press the control switch on the mower so that the door opens. Allow the door to open fully. If the actuator makes a ratcheting sound before the door stops moving then the angled sensor switch needs to be adjusted so that more of the plunger is exposed out of the switch s control body. The plunger depth is adjusted by loosening the two screws, repositioning the switch body, and then tightening the screws. Repeat the test and adjustment until the door stops its opening motion before the actuator ratchets.. With the door open, press the switch on the mower so that the door closes. The sensor switch should have a. second delay. Allow the door to close. The door should close and compress the door/shell joint and the actuator should ratchet and after approximately. seconds the ratcheting should stop. If the actuator does not ratchet then the horizontal sensor switch needs to be adjusted so that less of the plunger is exposed out of the switch s control body. If the actuator does not stop ratcheting then the horizontal sensor switch needs to be adjusted so that more of the plunger is exposed out of the switch s control body.. After the switches are correctly set, open the door and adjust the two turnbuckles by tightening them by two complete revolutions. tighten the jam nuts on the turnbuckles. Figure - Lock nut Turnbuckle Lock nut Blower Impeller Figure - Figure - The blower impeller shaft bearings do not require lubrication. WARNING Normal wear can cause the impeller and edges of the blower to become sharp. Wear gloves and use caution when servicing the blower. REV C - 79

31 Storage When your mower is to set idle for a period of time, scrape and power wash to remove the grass material from inside the BAC-VAC. Check for loose or missing hardware, tighten or replace. Also check for badly worn or damaged parts, consider replacing them at this time. Touch up chipped paint areas, your dealer has aerosol spray paint available 79 - REV C

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33 PARTS LIST 8" Deck Adapter " Deck Adapter " Deck Adapter Frame Shell Lid Linkage Frame Adapter Shell Electric Wire Harness Blower 099 S/N Prior to Blower S/N 0000 & Higher REV C

34 8" Deck Adapter REV C - 79

35 8" Deck Adapter INDEX NO. PART NO. QTY. DESCRIPTION 0 BLOWER OUTLET TUBE 0 OUTLET ADAPTER 09 CB.7- X.00 G ZNY 779 FW.0 X.8 X.00 SAE 00 7 NT.7- HX GRD ZNY 0 CS.7- X.000 HX G 7 9 BLOWER MOUNT 8 0 8" BLOWER BELT COVER W/ DECALS 9 0 DISCHARGE CHUTE DECAL DECK DANGERS DECAL 08 BELT, A 97.0" EL 07 CS.00- X.70 HX G 78 CW. X. X.0 BLK 009 8" DOUBLE PULLEY 88 8" BELT COVER BRACKET 009 CN.-8 X.00 MAX THK KNOB /-8 X /" 8 08 BLOWER BAFFLE, 8" 9 9 RS 8" BLOWOUT BAFFLE NT.7- HXZY NL 800 LS BAFFLE. Use existing parts and hardware. NOTES: 79 - REV C

36 " Deck Adapter REV C - 79

37 " Deck Adapter INDEX NO. PART NO. QTY. DESCRIPTION 0 BLOWER OUTLET TUBE 0 OUTLET ADAPTER 09 CB.7- X.00 G ZNY 779 FW.0 X.8 X.00 SAE 00 7 NT.7- HX GRD ZNY 0 CS.7- X.000 HX G 7 9 BLOWER MOUNT 8 0 " BLOWER BELT COVER W/ DECALS 9 0 DISCHARGE CHUTE DECAL DECK DANGERS DECAL 09 BELT, A 0.0" EL 07 CS.00- X.70 HX G 78 CW. X. X.0 BLK 00 " DOUBLE DRIVE 89 " BELT COVER BRACKET 009 CN.-8 X.00 MAX THK KNOB /-8 X /" 8 07 " BLOWER BAFFLE 9 0 RS " BLOWER BAFFLE NT.7- HXZY NL 80 LS BAFFLE. Use existing parts and hardware. NOTES: 79 - REV C

38 0" Deck Adapter REV C - 79

39 0" Deck Adapter INDEX NO. PART NO. QTY. DESCRIPTION 0 BLOWER OUTLET TUBE 09 7 CB.7- X.00 G ZNY 0 OUTLET ADAPTER 779 FW.0 X.8 X.00 SAE 00 7 NT.7- HX GRD ZNY 0 CENTER DRIVE COVER (WITH DECALS) 7 0 DISCHARGE CHUTE DECAL DECK DANGERS DECAL KNOB /-8 X /" " EL A-SEC BELT 07 CS.00- X.70 HX G 78 CW. X. X.0 BLK 0 0" DOUBLE DRIVE 8 BLOWER MOUNT 0 CS.7- X.000 HX G 009 CN.-8 X.00 MAX THK 7 77 CENTER DRIVE BRACKET 8 RIGID LINK 9 7 BLOWER BAFFLE 0 RS BLOWOUT BAFFLE 080 NT.7- HXZY NL 7800 LS BAFFLE. Use existing parts and hardware. NOTES: 79-7 REV C

40 Frame REV C -8 79

41 Frame INDEX NO. PART NO. QTY. DESCRIPTION 70 FRAME 8088 RIVET NUT, /-8 THREAD 09 GREASE FITTING STRAIGHT 090 DFS CATCHER DECAL 097 PINCH POINT DECAL /-0 THREAD RIVET NUT NOTES: 79-9 REV C

42 Shell SHELL FRAME SHELL REV C -0 79

43 Shell INDEX NO. PART NO. QTY. DESCRIPTION 079 LINEAR ACTUATOR 787 NT.00- NL G FW. X.0 X.090 SAE 790 CS.00- X.7 HX G Z NT.-8 HX ZY NL 78 FW. X.87 X.0/.080H SHELL CS.-8 X.7 HX G 9 97 INSIDE BAFFLE 0 78 TOP BAFFLE CB.-8 X.00 FULL ZN 78 SIDE BAFFLE 0 CB.-8 X.7 FUL ZN 70 VERTICAL SPANNER 70 SKID PLATE CS.00- X. HX G /-8 THREAD RIVET NUT 8 97 INLET TUBE NOTES: 79 - REV C

44 Lid REV C - 79

45 Lid INDEX NO. PART NO. QTY. DESCRIPTION 0877 NT.-8 HX ZY NL 78 FW. X.87 X.0/.080H 0 8 CS.-8 X.00 HX G 797 FW. X.00 X. HRD Z 99 SPACER CN.-8 X.0 MAX THK 7 88 SCREEN 8 0 CB.-8 X.7 FUL ZN 9 8 BOTTOM PLATE CB.-8 X.00 FULL ZN 0790 FW. X.00 X.0 ZNYC 00 CS.7- X.00 G ZNYC 779 FW.0 X.8 X.00 SAE 708 WHEEL 080 NT.7- HX ZY NL 7 LID FRAME LICENSE PLATE LID 9 ANCHOR BRACKET 0 78 SIDE BAFFLE 989 AIR DEFLECTOR 999 CENTER DIVIDER BRACKET NOTES: 79 - REV C

46 Linkage SHELL ASSEMBLY 8 7 LID ASSEMBLY REV C - 79

47 Linkage INDEX NO. PART NO. QTY. DESCRIPTION 0879 HINGE PIN 779 FW.0 X.8 X.00 SAE 0 CLIP 0 CB.7- X. G ZN 00 NT.7- HX G ZNY 0878 TURNBUCKLE FW.0 X.7 X. ZNYC 8 00 CS.7- X.7 HX G NOTES: 79 - REV C

48 Frame Adapter REV C - 79

49 Frame Adapter INDEX NO. PART NO. QTY. DESCRIPTION 709 CS.00- X. HX G ZN FW. X.0 X.090 SAE 790 MOUNT SPACER 907 RS MOUNT NT.00- HX G ZNYC 07 CS.00- X.7 HX G FW.0 X.7 X.8 ZNYC LS MOUNT KNOB /-8 X /" 0 WEIGHT LOCK PLATE 09 CB.7- X.00 G ZNY 08 CS.7- X.0 HX GR 779 FW.0 X.8 X.00 SAE 080 NT.7- NL G 7 WEIGHT MOUNT BUMPER WEIGHT 8 PLATE 9 00 NT.7- HX G ZNY 0 09 UB.7- X.00 X.00 SQ 07 FLEX TUBE 070 CE.0 X.0 X. X FW. X.0 X.0 ZN 00 HP.8 X.9 ZN 7999 SC #0 X.70 PHILLIPS T 077 MUFFLER EXTENSION.7" NOTES: 79-7 REV C

50 Shell Electric SHELL FRAME SHELL ASSEMBLY 7 REV C -8 79

51 Shell Electric INDEX NO. PART NO. QTY. DESCRIPTION 7 ACTUATOR TOP LID 8088 /-8 THREAD RIVET NUT CS.-8 X.7 HX G 78 9 FW. X.87 X.0/.080H CONTROL BOX COVER 08 NUT PLATE.0 CENTERS PLUNGER SWITCH 8 00 CONTROL BOX SWITCH 9 78 FW.8 X. X.0/.080 HD ZN/YL 0 09 CS.0-0 X. HX G 098 CS 0- X.7 HX FLK ZN 000 WIRE TIE 09 WIRE HARNESS 098 NT #0- HX NL ZN FW.0 X. X.0 SAE Z 007 CS 0- X.0 HX FLK ZN 7 7 ACTUATOR BOTTOM LID 8 N/A SERIAL NO. / SPEC DECAL. Part of wire harness. NOTES: 79-9 REV C

52 Wire Harness REV C -0 79

53 Wire Harness INDEX NO. PART NO. QTY. DESCRIPTION FRAME COVER (WITH DECALS) PUMP BELT WARNING DECAL 009 HOPPER POSITION DECAL ROCKER SWITCH 789 LS STEERING DECAL 009 CN.-8 X.0 MAX THK 7 0 CS.-8 X.00 HX G 8 78 FW. X.87 X.0/.080H WIRE TIE 0 09 WIRE HARNESS. Part of the wire harness. NOTES: 79 - REV C

54 Blower 099 S/N Prior to REV C - 79

55 Blower 099 S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION N/A BLOWER HOUSING (NOT SOLD SEPARATELY) 9 KEY.87 SQ X.7 LONG 09 PULLEY 0 CS.7- X.00 HX G 799 FW.0 X.00 X. HRD Z NT.-8 HX ZY NL 7 78 FW. X.87 X.0/.080H 8 0 BEARING.0" BORE FLANGE CB.-8 X.7 FUL ZN 0 90 BLOWER IMPELLER 097 NT.- HX G ZNYC 088 FW. X.00 X. ZNYC 009 DECK IDLER SPACER 79 IDLER PULLEY." OD X. 0 CS.- X.00 HX G Z 787 NT.00- HX G8 ZY NL FW. X.0 X.090 SAE 8 09 V-IDLER PULLEY BUSHING BUSHING 08 SPRING / COIL PL. 0 BLOWER IDLER ARM 0087 CS.00- X.0 HX G NOTES: 79 - REV C

56 Blower 099 S/N Prior to REV C - 79

57 Blower 099 S/N Prior to 0000 INDEX NO. PART NO. QTY. DESCRIPTION 7 BEARING COVER 9 BLOWER COVER CS.-8 X.0 HXFL KNOB /-8 X /" 8 0 CS.-8 X.00 HX G 9 8 DRIVEN PULLEY COVER CN.-8 X.0 MAX THK 080 NT.7- HX ZY NL 0788 FW.0 X.7 X. ZNYC 07 CB.7- X.00 STD 077 BLOWER DANGERS DECAL N/A SERIAL NO. / SPEC DECAL 7078 FW.0 X.88 X.00 ZNYC 7 0 TORSION SPRING BLOWER LID (WITH DECALS) EYES/EARS/FOOT DECAL FW.0 X.8 X.00 SAE 09 BLOWER CHUTE INLET 09 CB.7- X.00 G ZNY 8 BLOWER INLET BAFFLE 00 NT.7- HX G ZNY 07 FW.0 X.00 X.0 ZNYC 7799 CS.7- X.0 SOC BH BLOWER ASSEMBLY NOTES: 79 - REV C

58 Blower S/N 0000 & Higher REV C - 79

59 Blower S/N 0000 & Higher INDEX NO. PART NO. QTY. DESCRIPTION N/A BLOWER HOUSING (NOT SOLD SEPARATELY) NT.-8 HX ZY NL 78 8 FW. X.87 X.0/.080H 9870 TOP WRAPPER INSERT 0 7 CB.-8 X.7 FUL ZN 987 BOTTOM WRAPPER INSERT 7 90 BLOWER IMPELLER 8 0 BEARING.0" BORE FLANGE 9 09 PULLEY FW.0 X.00 X. HRD Z 0 CS.7- X.00 HX G 9 KEY.87 SQ X.70 LONG 7 BEARING COVER 987 BLOWER COVER 97 GUARD CS.-8 X.0 HXFL NOTES: 79-7 REV C

60 Blower S/N 0000 & Higher REV C -8 79

61 Blower S/N 0000 & Higher INDEX NO. PART NO. QTY. DESCRIPTION 7 08 NT.0-0 HX ZY NL 8 78 FW.8 X. X.0/.080 HD ZN/YL 9 0 COVER PLATE CB.0-0 X.7 FUL ZN 7900 KNOB /-8 X /" 0 CS.-8 X.00 HX G 0 PULLEY COVER 009 CN.-8 X.0 MAX THK 00 NT.7- HX G ZNY 779 FW.0 X.8 X.00 SAE 7 09 BLOWER CHUTE INLET 8 09 CB.7- X.00 G ZNY CS.7- X.0 SOC BH 0 07 FW.0 X.00 X.0 ZNYC 8 BLOWER INLET BAFFLE 080 NT.7- HX ZY NL 0788 FW.0 X.7 X. ZNYC 7078 FW.0 X.88 X.00 ZNYC 0 TORSION SPRING 099 BLOWER LID (WITH DECALS) ABRASION GUARD 8 07 CB.7- X.00 STD NOTES: 79-9 REV C

62 Blower S/N 0000 & Higher REV C -0 79

63 Blower S/N 0000 & Higher INDEX NO. PART NO. QTY. DESCRIPTION DECK IDLER SPACER 0 79 IDLER PULLEY." OD X. 088 FW. X.00 X. ZNYC 0 CS.- X.00 HX G Z 097 NT.- HX G ZNYC 787 NT.00- NL G 779 FW. X.0 X.090 SAE BUSHING BUSHING 8 08 SPRING / COIL PL. 9 0 BLOWER IDLER ARM CS.00- X.0 HX G 09 V-IDLER PULLEY 077 BLOWER DANGERS DECAL N/A SERIAL NUMBER / SPEC DECAL 078 EYES/EARS/FOOT DECAL BLOWER ASSEMBLY NOTES: 79 - REV C

64 REV C - 79

65 INDEX PAGE BAC-VAC Assembly...- BAC-VAC Hopper...- BAC-VAC Hopper Switch Adjustment...- BAC-VAC Mount Assembly...- Blower Drive Belt...- Blower Housing and Flex Tube Maintenance...- Blower Impeller...- Converting to side discharge mode...- Deck adapter kits...- Final Connection...-8 Frame Cover Assembly Installation...- Lid latch adjustment...- Mower deck preparation...- Mower Preparation...- PAGE Packing List Hustler X-ONE BAC-VAC...- Parts and service...- Removing The BAC-VAC...- Safe Operation and Service Precautions...- Safety and Instruction Decals...- Storage...- To the new owner...- Unloading the BAC-VAC...- Using this manual...- Vacuum Pickup and Collection...- Warranty registration...- Weight Assembly & 90 Adapter Assembly Adapter Assembly i- REV C